This Tutorial will help newbee to understand the welding process and its trouble which are easy to sort out during the production. Just follow the tutorial and boost your knowledge to understand the welding process.

1. Welding O.E’s Kit
For New Joiners.
Welding is a Fabrication or sculptural process that joins the material, Usually
Metals or thermoplastics, by causing coalescence. This is often done by melting
the work pieces and adding a filler (may be and may not be) material to form a
pool of molten material that cools to become a strong joint, with pressure
sometimes used in conjunctions with heat, or by itself, to produce the weld. This
is in contrast with soldering and brazing, which involves melting lower-melting-
point materials between the work pieces to form a bond between them, without
melting the work pieces.
2012
Planned and Prepared by Sourbh Kumar & Suriya Praba
Mando India Ltd.
7/12/2012

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Contents:-
1. Introduction and Welding History ……………………………………………………..….…1
2. Basic work Practice…………………………………………………………………………………2-3
3. Head Cap Pressing Machine…………………………………………………………….………4-6
i. Introduction
ii. Loading and unloading of component
iii. Inspection
iv. Setup change Procedure
v. Work Standard
4. Projection Welding………………………………………….…………………………..………..7-17
I. Introduction
II. Projection welding Components
III. Loading and unloading of Component
IV. Inspection using Various Gauges
V. Set Up Change Procedure
VI. Welding Defects
5. GMAW Welding………………………………………………………………………..……………..18-23
i. Introduction
ii. GMAW welding Components
iii. Loading and unloading of component
iv. Inspection
v. Troubleshooting
6. PPE’s ……………………………………………………………………...…………….…………………24-25
7. My Notes……………………………….…………………………………………………………..……26-26
8. General Awareness Program……………………………………………………………………27-29
9. Pneumatics and Hydraulics Definition………………………………………..……….…..30-31
10. Conclusion………………………………………………………………………………………..……32-32
11. References………………………………………………………………………………………..……33-33

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Acknowledgement
I Wish to Express My sincere thanks to Mr. Ravi Kumar,
Manager- Mando India Ltd for giving his Valuable Guidance,
Advice and Encouragement to complete this Project.
My Sincere thanks to Mr. Balaji.K Asst. Manager- Mando India
Ltd., Mr. Jai Prasad Rai (J.E.) and Miss Anita (Shell coordinator)
for his support & Implementation of this project.
And also sincere thanks to Miss Suriya Praba my co-worker and
Project Planner for his whole Hearted support, motivation and
help in making our Project Activities.
Thanks all of Guys who supported to complete this project.
Sourbh Kumar.

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Introduction and Welding history
Welding is a Fabrication or sculptural process that joins the material, Usually
Metals or thermoplastics, by causing coalescence. This is often done by
melting the work pieces and adding a filler material to form a pool of molten
material that cools to become a strong joint, with pressure sometimes used
in conjunctions with heat, or by itself, to produce the weld. This is in contrast
with soldering and brazing, which involves melting lower-melting-point
materials between the work pieces to form a bond between them, without
melting the work pieces.
Many Different energy sources can be used for welding, including a gas
flame, an electric arc, a laser, an electron beam, friction, and an ultrasound.
*Until the end of 19th century, the only welding process was Forge Welding,
which blacksmiths had used for centuries to join iron and steel by heating
and hammering.
The History of Joining of metals goes back several millennia, called Forge
welding, with the earliest examples of welding from the Bronze Age and the
Iron Age in Europe and the Middle East.
Resistance Welding was developed during the final decades of the 19th
Century with the first patents going to Elihu Thomson in 1885, which
produced further advances over the next 15 years.

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Basic work Practices
While coming to work in Shop Floor/Welding machine, ensure that you
are with.
1.) Uniform
2.) Safety Shoes
3.) Safety Google’s
4.) Skill Badge
5.) Gloves
6.) Ear- plug
Before start of the Shift
i.) Read the Previous shift Production log book, communication
report.
ii.) Verify the Due date for the gauges with the gauge calibration Sheet,
and Inform to concerned person incase of due date over.
iii.) Check the machine as per check list. Please pay attention to the
check points. If any points not meeting the Requirements
immediately In-form to Cell coordinator.
iv.) Ensure that no components are on the floor. If any remove and
reject them.
v.) Clean the Machine, warming up the machine for 2-3 Cycles.
vi.) Ensure No Pneumatic/Hydraulic pipe Leakage, oil Spillage, Gas
Leakage. If Available Arrest the Leakage and Inform to Concern
Person.

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During work:-
i.) Wear Suitable gloves/safety shoes/goggles wherever required.
ii.) Report any Unusual Noise/Heating/Vibration/behavior of machines.
iii.) Never by pass any safety provisions in the Machines.
iv.) Follow the Work Instruction and Work Standard as per Given.
v.) Follow first off, middle, End procedure as per standards.
vi.) Do Check the Component dimension and Machine parameters time to
time.
vii.) Any Deviation in process must be approved in writing by Quality Dept.
head.
viii.) Put the Rejection components in Appropriate Red bin after Marking.
ix.) Please don’t keep any components, bins on the floor.
x.) Do not re-use Salvaged Components without Q.C Approval.
xi.) Ensure Clear visibility of Tags and Mark on Specific components.
xii.) Discuss any Implementation in C.I. team Activities.

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Head Cap Pressing Machine
Introduction: -
Head Cap Pressing Machine Provides the simple temporary joint to
head cap & piston rod by the Application of Hydraulic and
Pneumatic Pressure, due to Dimension of hole in Head cap and Rod
up side Having Approximately same that way whenever we forcing
both on each other, Its Getting a temporary Joint.
Loading and Unloading Procedure: -
First Put the Head cap into the bottom fixture of machine, than in
head cap put the rod straightly (Threaded side Up) with respect
to supporting guide unit [magnetic V-type], Check for Pressure
and all other Settings related to Required model than Press the
Both Push button Simultaneously same time to Start the Cycle.
After Cycle Completion take out the finished component, check it
for “No Gap” between the Head cap & Eye. Than Continue the
process of reloading and unloading.
Inspection: - Check Gap, Pressure and Other Parameter’s Time to
Time.

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Setup Changing Procedure:-
First Avoid Component Loaded condition,
i.) Press Function Key Select the LL ( Lower Limit)
If your next Product is PA than Check out the Work Standard
for Lower Limit value like is 12.2 Select it by pressing up down
Key.
ii.) Than similarly select the HL (Higher Limit), set it to 13.2.
iii.) When you done Editing the LL and HL Press ok and Than
Press Tare for Set the Indicator in Zero Position. Home
Position.
Note:-
LVDT means “Linear Value Differential Transform” And don’t
forget to put Permanent mark on PB models Cap Inside.
Here is Some Model and its LVDT Value, Work Standard:-
Models LVDT
PA 12.7±0.5
PB EC 9.7±0.5
PB DOM 4.5±0.5
RBI 6.3±0.5
HA 11.6±0.5

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1. Pressing Pressure:- 40-60 kg/cm²
2. LVDT: - As per Table
3. Air Pressure: - 4.5 Kg/cm²
4. Pallet condition: - No dust and Free from Extra material Like
Chip etc.
5. Rod Length: - PA- 188±0.5mm
PB- 195±0.5mm
RBI- 194±0.5mm
HEAD CAP PRESSING MACHINE
PROJECTION WELDING MACHINE
GMAW WELDING

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Projection/Resistance Welding Machine
Introduction:-
Resistance welding involves the generation of heat by passing current
through the resistance caused by the contact between two or more metal
surfaces. Small pools of molten metal are formed at the weld area as high
current {1000-100,00A} is passed through the metal.
In general, resistance welding methods are efficient and cause little
pollution, but their applications are somewhat limited and the equipment
cost can be high.
The Principal of projection welding is the joule heating law where the heat
Q is generated depending on three basic factors as expressed in the
following formula:
Q=I² rt
Where “I” is the Current Passing through the metal combination, “R” is the
resistance of the base metals and the contact interfaces, and “t” is the
duration/time of current flow.

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While Startup, Things to be Follow:-
1. Check the Clamping and Welding Pressure ;( it is interlinked with
machine sensors which will give alarm whenever the Pressure drops).
2. Check the Flow of Water in the Pipe line, Ball to be Rotate inside the
Flow meters.
3. Check the Gap between the Head cap and Eye after pressing through
the head cap pressing machine.

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4. Check for Correct weld controller number, Program as Default stored
in 01 Number- but for Confirmation ask to Senior O.E’s or Shift In-
charge.
5. Check the Working of the weld checker and the Specification.

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Projection Welding Defects
ok Not Ok ok Not Ok
Welding Gap Problem Heat Marking Problem
ok Not Ok ok Not Ok
Welding Extra Material Eccentricity Problem

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ok Not ok
Tilt Problem
Things Need To correct when above problem occurred:-
1. Gap Problem:-
Welding Gap Between Piston Rod
And head Cap.

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First Check Pressing Pressure in
Head Cap Pressing Machine.
Check Presence of gap after head cap
pressing.
Set up change time bottom fixture
change correctly.
Cycle start in auto mode but weld
should be off. After cycle completion
Check for Gap.
After Welding, Check Visually First
And then measure the height of
component in height gauge.

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2. Tilt Problem:-
Head cap tilt problem
*Due to clamp electrode improper
alignment.
*Put m/c in manual mode & check
clamping position in forward
condition.
**Adjust the electrode holder up
to the proper position.

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3. Eccentricity Problem:
Tilt gauge
*Cycle start & after completion
check the First welded component
assembly Through tilt gauge.
Eye eccentricity problem
(Horizontal)

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Top electrode alignment problem
**Put one identification mark on
front side of head Assy for
reference & check eccentricity
**If eccentricity is +ve more than
spec, move electrode to left side
and vice versa.
Check eccentricity

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Eye eccentricity problem
(Vertically)
**Put one identification mark on
front side of head Assy for
reference & check eccentricity
**If eccentricity is +ve more than
spec, move electrode to back by
rotating shaft in anti-clock wise
direction and vice versa.

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GAS METAL ARC WELDING MACHINE (GMAW)
Introduction:-
The Gas metal Arc welding process (GMAW), often called MIG (METAL
INERT GAS), has revolutionized arc welding in this process, a Consumable
Electrode (In form of wire) is fed from a spool through the torch (welding
gun) at a present Controlled Speed. As the wire passes through the
contact tube of the gun its picks up the welding current. The Consumable
wire Electrode serves two Functions: it maintains the arc and provides
filler Metal to the joint. The Method of Delivery of the filler Metal allows
GMAW welding to be basically a one-handed operation.
The MIG Process uses a direct current power source, with the Electrode
positive (DC, EP). By using a positive electrode, the oxide layer is efficiently
removed from the Aluminium (Al) or Metal Surface, This is essential for
avoiding lack of fusion and oxide inclusions.
The Metal is transferred from the filler wire to the weld bead by magnetic
forces as small droplets, spray transfer. This gives a deep penetration
capability of the process and makes it possible to weld in all positions. It is
Important for the quality of the weld that the spray transfer is Obtained.
High rate metal Deposition result in minimum Distortion, and also GMAW
offers many Advantages.
Since there is no flux, GMA welds are Clean and there is no slag to remove.
GMAW enables you to produce sound welds in all positions quickly.
Gases using in GMAW welding:-
Argon:- Argon provides greater cleaning action than other gases. Because
it is heavier than air, Argon blankets the weld from contamination. Also,

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when you are using Argon as a shielding gas, the welding arc tends to be
more stable. For this Reason, argon is often used combination with other
gas.
Argon Reduces spatter by producing a quiet and reducing arc voltage that
results in lower power in the arc and thus lower penetration.
Carbon Dioxide: - Argon consists of single atoms. Carbon dioxide on other
hand consists of molecules. Each Molecule contains one carbon atom and
two oxygen atoms. At Normal temperatures carbon dioxide is essentially an
inert gas; however, at high temperatures is decomposes into carbon mono-
oxide (CO) and Oxygen (O). because the Excess oxygen atoms can combine
with carbon or iron in the weld metal, wires used with this gas must contain
de-oxidizing Elements.
Carbon oxide is used primarily for the GMA welding of Mild Steel. Because
of low cost.
Note:-
In our Company we are using the Argon and Carbon Dioxide Combination at
the Ratio of 80:20.
**Argon & Carbon Dioxide Cylinder: - Yellow Color.
**Nitrogen Cylinder: - Thick Blue

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Work Standard
Operating Procedure:-
i.) Check the Manufacturing condition and error proof.
ii.) Load the component to the machine.
iii.) Press Cycle Start( Pressing both Push Button simultaneously)
iv.) Unload the Component and follow Inspection Standards.
v.) Repeat the Process 2-4 After Satisfied with first Weld.
Action on Error:-
i.) Machine Error:- Inform Maintenance Team
ii.) Incoming Material error: - Inform Quality control Team.
iii.) Process Error: - Inform the Shift In-charge of Q.C Team.
Manufacturing Condition control standard: - Prefer the Work standard
Available in top of Machine front.
In GMAW machine Torch Cylinder is Anode and Work Clamping/Guiding
Fixture is Cathode.

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GMA Welding Defects
Porosity:-
Cause:-
i.) Loss of Shielding Gas due to High Travel Speed.
ii.) Flow Rate too Low.
iii.) Flow Rate too high.
iv.) Impure gas.
v.) Non Protection of shielding gas due to wind or Draft
(which is usually coming because of Leakage of
Pneumatics Pipe which is used to rotate the fixtures or
moving the torch tip forward and backward.
vi.) Off Countering of Filler Wire (Mis Alignment).
vii.) Excessive Current, over Heat the Electrode and losses its
De-Oxidizers and alloying element (Problem in Wire).
viii.) Improper Cleaning of Base material, improper storage of
filler Material.
Remedy:-
i.) Reduce the Travel Speed.
ii.) Increase/Decrease the Gas Flow Rate.
iii.) If impure gas, than use purified grade instead of
Commercial Grade.
iv.) Be sure of Air Leakage, if any fix it.
v.) Adjust the Filler Wire Exactly to the Centre.

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vi.) Reduce Current.
vii.) Proper cleaning of the material should be done with
Chemical, Sand Paper, Brush or Scrapped.
viii.) Store the Filler Material spool in Clean Place.
Excessive Penetration:-
Cause:-
i.) Too Much Heat Generated during Welding.
ii.) Excessive Voltage.
Remedy:-
i.) Reduce the Wire speed and Increase the Travel Speed.
ii.) Check for weld parameters Like Current, Voltage and Gas
flow rate.
Weld Cracking:-
Cause:-
i.) Compositional problem of filler Materials (Wire Spool not
good)
ii.) Different Welding Parameters.
Remedy:-
i.) Select the proper good condition of Filler wire spool.
ii.) Clean the Fixtures/Torch Nozzle and Orifice to remove
the Carbon and Extra materials deposit.

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iii.) Weld with proper parameters.
Sensor’s in GMA Welding Machine:-
1.) Proximity Sensor: - You clearly able to see this sensor in bottom
side of machine fixture just open the bottom door and check it out.
It’s attached to a strip and to Guiding this Rectangular plate is
attached with the Rotating Fixture.
A proximity sensor is a sensor able to detect the presence of nearby
objects without any physical contact.
A proximity sensor often emits an electromagnetic field or a beam
of electromagnetic radiation (infrared, for instance), and looks for
changes in the field or return signal. The object being sensed is often
referred to as the proximity sensor's target. Different proximity sensor
targets demand different sensors. For example, a
capacitive photoelectric sensor might be suitable for a plastic target;
an inductive proximity sensor always requires a metal target.
A proximity sensor adjusted to a very short range is often used as a touch switch
2.) Optical-Fibre-Based Gas Sensor Systems: - this Sensor is
placed at the bottom of control panel front Right side of
machine, and use for Sensing the Amount of Gas is Flow
from the Nozzle means its Generally Indicate and monitor
the Amount of Gas flow, if not than Alarm coming
continuously.

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PERSONAL PROTECTIVE EQUIPMENT
The Projection and GMA Welding machine were using the More Amount of
Current, voltage and Heat Generation. So we should and must have to use
the Personal Protective Equipment for our Safety.
Here is the List of them:-
i.) Goggles: - In welding machine (Especially projection) Emit more
sparks and Smoke which is not good for our Eyes, so we must have
to use this PPE.
ii.) Mask: - As we well know that, Wherever the Term Welding
Employed means Smoke must be there, so To Ensure prevention of
Health Hazard we must have to Wear Mask While Working with/In
Welding Machine.
iii.) Gloves: - Due to Welding is an application of Heat and Electricity
that way must needs to Wear Gloves to protect ourselves from
Burning and Electrical shock. For Welding a special type of
Gloves is Available ask for it.
iv.) Ear Plug: - In our company the welding machine is placed just near
to the Compressor Unit, so “I suggest Using the Ear Plug”. But this is
Just our Choice to use it or not.

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v.) Safety shoes: - While coming to Machine Shop floor, you are
working or not matter should and must wear the Safety shoes to
avoid the Accident Related to Falling Heavy/Sharp Component in
your Legs.
Note: - All girls must tie their hair properly for Safety Purpose.

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My Notes:-
Q. Why Rejection Can Happen?
Ans: - 1.Operator By Passed The Process.
2. Basics Work Practices Are Not Followed.
3. Initial Inspection Not Carried
4. Lack of Concentration.
**Lists Of Welding Quality Issues:-
a. Gap Problem
b. Eccentricity Problem
c. Tilt Problem
d. Heat Marking
e. Extra Material
f. Weld Spatter Problem
**When above Problem Occurs?
i. Improper Height Adjustment During setup change.
ii. Bottom Fixture not tightened properly.
iii. Initial Inspection Not Carried.
iv. Lack of Concentration,
v. Electrode Not Dressed Properly.
vi. Water Circulation Problem.
vii. Clamp Electrode Alignment Problem.
viii. Top Electrode Alignment Problem.
ix. Due to Improper Cooling Of electrode.

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AWARNESS PROGRAM FOR PROJECTION WELDING MACHINE
**Things need to Verify during the abnormal situation like power off/while
process/ while startup of machine.
1. While Process: - Like power cut During the Cycle time!!
Ans:-
i. Remove the component and put in Rejection bin.
ii. Check the Inner Surface and Outer Edge of the Electrode for any burr and
uneven face.
iii. Check the Height of Electrode.
Rejection Bin Electrode’s
When rejection can happen?
1) Operator bypassed the Process.
2) Basic work practices are not followed.
3) Initial inspection not carried.
4) Lack of concentration

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2. After Every Break time, we have to do Bending test, if any
Problem coming means what we do.
Ans:-
i. Incase of weld broken without the parent material stop the Production.
ii. Every one hour needs to do bending test.
Not ok Ok
3. Reject the component In following Condition:-
Ans:-
i. Heat Mark coming/Black Mark coming.
ii. Gap Presence between Head cap & Eye.
iii. Spatter in Rod.
iv. Spiral mark in rod.

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4. Things to Check in Regular Based.
Ans:-
i. Weld parameter must be with in Specification.
ii. Check the air Pressure time to time.
iii. Don’t use the Disk below the Bottom jig, Spacer has to be use for
PB – 6.2mm, and for PA – 6.8mm.
iv. Check Water flow in Machine Line.
Note: - If any Variation Coming During the Work than Kindly
inform to Senior O.E’s or to shift in charge.

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Pneumatic systems
Most pneumatic circuits run at low power -- usually around 2 to 3 horsepower. Two
main advantages of air-operated circuits are their low initial cost and design simplicity.
Because air systems operate at relatively low pressure, the components can be made
of relatively inexpensive material -- often by mass production processes such as plastic
injection molding, or zinc or aluminum die-casting. Either process cuts secondary
machining operations and cost. First cost of an air circuit may be less than a hydraulic
circuit but operating cost can be five to ten times higher. Compressing atmospheric air
to a nominal working pressure requires a lot of horsepower. Air motors are one of the
most costly components to operate. It takes approximately one horsepower to
compress 4 cfm of atmospheric air to 100 psi. A 1-hp air motor can take up to 60 cfm
to operate, so the 1-hp air motor requires (60/4) or 15 compressor horsepower when
it runs. Fortunately, an air motor does not have to run continuously but can be cycled
as often as needed. Air-driven machines are usually quieter than their hydraulic
counterparts. This is mainly because the power source (the air compressor) is installed
remotely from the machine in an enclosure that helps contain its noise. Because air is
compressible, an air-driven actuator cannot hold a load rigidly in place like a hydraulic
actuator does. An air-driven device can use a combination of air for power and oil as
the driving medium to overcome this problem, but the combination adds cost to the
circuit. (Chapter 15 has information on air-oil circuits.)Air-operated systems are always
cleaner than hydraulic systems because atmospheric air is the force transmitter. Leaks
in an air circuit do not cause housekeeping problems, but they are very expensive. It
takes approximately 5 compressor horsepower to supply air to a standard hand-held
blow-off nozzle and maintain 100 psi. Several data books have charts showing cfm loss
through different size orifices at varying pressures. Such charts give an idea of the
energy losses due to leaks or bypassing.

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Hydraulic systems
A hydraulic system circulates the same fluid repeatedly from a fixed reservoir that is
part of the prime mover. The fluid is an almost non-compressible liquid, so the
actuators it drives can be controlled to very accurate positions, speeds, or forces. Most
hydraulic systems use mineral oil for the operating media but other fluids such as
water, ethylene glycol, or synthetic types are not uncommon. Hydraulic systems
usually have a dedicated power unit for each machine. Rubber-molding plants depart
from this scheme. They usually have a central power unit with pipes running to and
from the presses out in the plant. Because these presses require no flow during their
long closing times, a single large pump can operate several of them. These hydraulic
systems operate more like a compressed-air installation because the power source is
in one location.
A few other manufacturers are setting up central power units when the plant has
numerous machines that use hydraulics. Some advantages of this arrangement are:
greatly reduced noise levels at the machine, the availability of backup pumps to take
over if a working pump fails less total horsepower and flow, and increased uptime of
all machines.
Another advantage hydraulic-powered machine has over pneumatic ones are that they
operate at higher pressure -- typically 1500 to 2500 psi. Higher pressures generate
high force from smaller actuators, which means less clutter at the work area.
The main disadvantage of hydraulics is increased first cost because a power unit is part
of the machine. If the machine life is longer than two years, the higher initial cost is
often offset by lower operating cost due to the much higher efficiency of hydraulics.
Another problem area often cited for hydraulics is housekeeping. Leaks caused by poor
plumbing practices and lack of pipe supports can be profuse. This can be exaggerated
by overheated low-viscosity fluid that results from poor circuit design. With proper
plumbing procedures, correct materials, and preventive maintenance, hydraulic leaks
can be virtually eliminated. Another disadvantage could be that hydraulic systems are
usually more complex and require maintenance personnel with higher skills. Many
companies do not have fluid power engineers or maintenance personnel to handle
hydraulic problems.

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Conclusion
This Project Aims at Introducing Welding Technology to the
New Joiners to make it easy to Understand and work on
machine. In An Entirely Different Way That Has Been Little
Distant Till Now. But The Pace In Which The People were
Interested in Welding Process, This Seems That Very Soon; We
Will Be In An Environment of Pervasive Automated Welding
Technology In Manufacturing Field. Where the Human and
Machine Will Be Interact In the Informal Way, the Way in
Which human Communicate with Each Other.

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References:-
Many Texts Have Been Referred While Doing Work on Project
Entitled of “Welding Process New O.E’s Kit”. Following Is the List
of Them:-
1.) Course material by Foreman Training Institute.
2.) Google Search.
3.) Work piece Image Credited by J.p sir and Anita Miss.
4.) My Notes any Training material provided by Mando India
Ltd.
Thanks